Casting apparatus.



J, KRALUNDY& M. STERN.

, CASTING APPARATUS.

APPLICATION FILED -,uc.|0. 1917.

Patented Jan. 28, 1919.

2 SHEETSSHEET 1.

3 51 G-Hozwz J. KRALUND & M. STERN. CASTING APPAR'ATus.

APPLICATION FILED AUG.10. 19H.

' 1,292,484 Patented Jan. 28,1919;

2 SHEETSSH EET 2.

IIP'I,

E TEs P TENT OFFICE.

JOHN KRALUND, OF NEW YORK, N. Y., AND MARCUS STERN, OF TOLEDO, OHIO, ASSIGNOBS TO DOEHLER DIE-CASTING COMPANY, OF BROOKLYN, NEW YORK,

A CORPORATION OF NEW YORK.

CASTING Arrmrus.

Specification-0t Letters Patent.

Patented Jan. 28, 1919.

Application filed August 10, 1917. Serial No. 185,429.

To all whom it may concern:

Be it known that we, JOHN KRALUND and MARCUS STERN, both citizens of the United States, residing, respectively, in the borough of Brooklyn, city of New York, county of Kings, and State of New York, and at T0- ledo, in the county-of Lucas and State of Ohio, have jointly invented certain new and useful Improvements in Casting Apparatus, of which the following is a speclfication, reference being had therein to; the accompanying drawings, which form a part thereof;

Our inventlon relates to casting apparatus and more particularly 'to a type thereof in which molten metal 'is forced from a cylinder into a metal die in making pressure die castings.

An apparatus made in accordance with our invention is specially adapted for making castings of the lower fusion white metal alloys, and is automatic to the extent that the rate of flow of the metal into the die, the force or pressure exerted upon the 'metal mechanically'controlled. This permits the production of a large number of castings under identical pressure conditions; avoids those varlatlons 1n castlngs resulting from the impossibility of a man always applying the same force to'the plunger oroperating it at the same rate of speed and gives greater capacity to the machine as compared with hand operated machines.

In a machine made in accordance with our invention, wherein the metal is forced from the pressure cylinder by means of-a mechanism utilizing fluid pressure, such as compressed air or steam, the range of the sizes of the casting which may be produced is very much increased, as compared with hand operated machines, and the working conditions about the machine are the same, irrespective of the size, or weight, of the casting being made. The main advantage secured by 'a machine made in accordance with our invention, however, is the elimination of man-power in actuating the machine while preserving all of those conditions which are essential to secure a proper and rapid filling of the mold and uniformity in the density of the metal in succeeding castings.

the mold or die, resulting from the adjustment of the machine and not being depend ent upon the operator thereof. It is referable to use a double acting piston, wlth a valve so constructed as to cause the actuation thereof to open an exhaust port communicatingwith one side of said piston when the inlet port communicating with the other side thereof, is opened.

By utilizing an elastic fluid pressure, we are enabled tonot only secure the desired rapid movement of the plunger with the variable pressure conditions in the pressure cylinder above referred to, but to secure a variable thrust of the plunger in proportion to the volume of metal requiredto fill any mold, and an automatic increase in the power exerted upon the plunger in proportlon to the increase in the slze and weight of the casting.

In the accompanying drawings, we have illustrated our invention in connection with a well known type of casting apparatus omitting therefrom ashowing of the die support and rigging, such being immaterial to a full understanding of the invention, and being wellknown to those skilled in the art.

The invention consists primarily in a cast ing apparatus embodying therein a melting pot, a pressure cylinder communicating therewith, a plunger mounted in said pressure cylinder, an actuating lever, one arm of which is operative upon said plunger, a power cylinder, apiston mounted therein, operative connections between said piston and the other arm of said lever, connections between said power cylinder and a source of fluid under pressure, and a valve mechanism controlling the flow of said fluid to and from said power cylinder, and in such other novel features of construction and combination of parts, as are hereinafter set forth and de- I scribed and more particularly pointed out in the claims hereto appended. Referring to the drawings: Figure lis an end View of an apparatus embodying therein our invention;

Fig. 2is a-side view thereof partly in sec tion; 3 is an end view'of the controlling valve;

Fig. 4 is a section on the line 4-4 of Fig. 3 with the valve'block' set for restoring the parts to their normal operative positions; Fig. 5 is a similar section with the valve blockset in a manner to cause the actuation of the plunger to inject metal into the mold or die; and i Fig. V6 is a cross section of the valve key. Like letters refer to like parts throughout the several views.

In the embodiment of our invention shown in the drawings, it indicates a. furnace casing having mounted within same a melting pot an adapted to contain molten metal heated from the furnace. Said melting pot has asuitable closure top a Supported from;

' and positioned within, the melting pot a is apressure cylinder, 6 having an outlet nozzle 1) and ways b suitably'spaoed apart and projecting from. the open-end thereof. Slida ly mounted in said cylinder 1) is a piston 0 having an undercut end 0' .so that when the piston is withdrawn from the bore of the cylinder and supported entirely by the ways 6 metal may-flow froni'the central portion of the melting pot into saidcylinder., The construction and arrangement heretofore described is old and well known in this art, as is the rigging for supporting the die with the ingate thereon adjacent the nozzle 6. for which reason said ri'ggingis not illustrated inthe accompanying drawings.

Heretofore the piston or plunger f0 has been manually actuated for forcing the metal from the-cylinder 6 into the mold or die, by means of a hand lever; v

In our present invention this piston is actuated by 'fluid pressure, such as compressed air or steam. In the form of the invention shown, this mechanism comprises a power cylinder 1 having mounted therein a piston e' operatively connected with the piston or plunger 0. In order to utilize fluid pressure for impartingmovement to the plunger in both directions, we use a double acting piston, mounted in a cylinder closed at both ends and provide means for controlling the flow of the fluid under pressure alternately upon opposite sides of said piston and means whereby the fiuid upon one side ofsaid piston will be automatically exhausted when the fluid is admitted to the other side thereof. Connected with the stem e of the piston e is a cross head f mounted upon suitable guide rods f. Pivotally neeaese ,the connecting rod h pivotally connected to said other arm of .said lever, and to said cross head respectively. The lever g is so formed that when the piston e is in the uppermost position, as

shown in Fig. 2 the point of pivotal connection between the connecting rod h and the lever y will be off center and the piston or plunger 0 will be entirely withdrawn. from the cylinder 6, soas to insure a proper starting. of the piston or plunger, while at the same timeinsuring a low starting leverage with a gradual increase in thisleverage as the piston descends. In this. manner,

we not only secure the maximum applied pressure in making a casting, but the power applied to the plunger W llbe increased to adapt themechani'sm to the making of castings of difl'erent sizes. Where a-large casting is made it is not only necessaryto force a largerquantity of metal from the pressure cylinder 6 but the final pressure upon the molten metal in the die must be greater to secure the desired compaction of this metal.

The means for controllingthe flow of the fluid to the cylinder (1 is so constructed as to insure a slow return movement of the piston e and avoid. the splashing of the molten metal about the melting pot a'..

Leading to. any desired source'of power of fluid under pressure, is apipe line i having arranged therein a drain cock 2' .and a controlling valve 6 Communicating with the pipe line i is a pressure gage i The means for controlling the flow of the 'fiuid from the pipe line 2'', in the form of the invention shown. consists of a valve mechanism having a casing provided with an intake port 1' with which the pipe line i communicates and two outlet ports y' j'"', one of which communicates through the pipe 1, with one end of the cylinder 61 and the other of which communicates through the-pipe 9' With the other end of said cylinder, said cylinder being provided with ports suitably formed to insure the proper delivcry of the fluid passing therethrough, to or from said cylinder. The-ports j 7' are arranged in substantially the same plane. the port 1" being oif-set in relation to said other ports in said casing j. Rotatably mounted in the casing j is a valve key k having therein a bore 70 opening outwardly. thereof into atmosphere or any other point for discharge of the fluid. Said key has therein a port 70 leading from said bore and adapted to communicate successively with the ports j -j Saidkey is also provided with a circumferentially' extending channel madapted at all times to be in com-- -channel a willbe in communication with the port 7'.

- pin p adapted to engage portions of the y directions.

The valve key 70 is tapered, as shown, being acted upon by a spring 0 encircling a rod 0 carried by the key [0 and acting against a spring seat 0 in a manner to normally draw said key within its casing and insure an automatic readjustment of the valve to its seat, to compensate for any possible wear. The end of the saidkey is '20 provided with an angular portion p adapted to be engaged by a recess in the operating handle p.

The valve casing is provided with a stop operating handle 2' extending upon opposite sides of the axis of the key is and limit the oscillatory movement of said lever in both The operation ,of the herein described apparatus is substantially as follows Normallythe piston 6 will be in its uppermost position, the cross head fbeing 7 drawn upwardly in a manner to so position the lever g as to bring the plunger or piston c entirely without the cylinder ,6 and-within the ways I). When the parts are in this position, the metal ma readily flow into the cylinder from a point in the melting pot, intermediate theuppermost and lowermost strata of the molten metal therein, thus insuring delivery of clean metal to the cylinder. 1 When the parts are in this position, the extension n of the port a is in communication with the port j delivering fluid under pressure to the cylinder upon one side of the piston e, and the port is is in communication with the port 7' placing the cylinder d upon the other side of the piston e in communication with atmosphere through the bore k..

When the machine is properly set for casting, the key is is turned by means of the handle 72 bringing the port n" in register with the port jf, and the rt k in register with port y' thus delivering the fluid pressure upon the upper side of the piston e while resenting a clear passage to atmosphere hrom the lower side of, said piston, to permit the exhausting of the fluid pressure therein. When the lever 10' has been actuated'to an extent to bring the various cooperating ports into full register, the end hereof projecting beyond the key will engage the stop pin 15.

As the flllld under pressure enters the up-v per portion of the cylinder d above the piston e, the cross head f will descend at uniform speed it the power be applied with one, movement of the key, or with a gradual acceleration, if the movement of the key be gradual. 'The control of the force with which the metal is forced from the pressure cylinder 6 is not, however, dependent upon a variable piston Speed but results solely from the construction of the apparatus, or of the connections intermediate said power piston e and the piston 01' plunger 0.

As the cross head f begins to descend, the leverage at which the connecting rod It acts upon the lever 9, will be the minimum for which the machine is set, the construction of this lever 9 being such that the movement of the plunger or piston c with its maximum movement, will be adually accelerated during the first portnon of it stroke and,

gradually 'retarded toward" the end of its stroke. As the arm of the lever g to which the connecting rod k is connected, swings outwardly and downwardly, the leverage at which the said connecting rod 'acts will gradually increase reaehin its maximum toward the end of the effective stroke of the said piston .0, which stroke will vary in length, according to the volume of metal required to be forced from the pot to 'fill the die.- If this volume of inetaljbe small,

'ment of the piston e and greater oscillation of the lever g with a'resultant gradual increase in the speed at which the plunger 0 will be advanced in its cylinder and the pressure exerted upon the metal within the die cayity toward the end of the stroke will be proportionately increased. Hence, the rapid charging of the die-and'the develop;-

,ment of pressure upon the. metal therein,

when the die or mold is completely filled, proportionate to the needs of any particular casting, is insured. It will be observed that the machine automatically adjusts itself to any size of casting to be made, irrespective of the manner in which the key It ma be actuated or of the manner of applymg'the pressure to the pi'ston e.

It is desired to point out that the filling of the mold limits the movem'ent ot the piston or plunger 0 and also that of the piston e. Hence,t e piston e isan automatically controlled, variably movable piston, adapting After the piston e has reached the limit of its downward stroke, a return of the valve key is to normal is delayed momentarily to maintain pressure upon the metal in the die cavity until initial solidification has occurred, or until any tendency of the metaltc flow from the die through the ingate thereof is passed. If a sprue cutter beused, the pressure is maintained until saidsprue cutter has been actuated.

When the casting ha been thus made, the key 70 is restored to its former position as definedby the engagement of the handle p with the stop pin [2 b'ringingthe port-s in the position shown in Fig. 5 of the accompanying drawings. When the ports are in this position, the upper portion of the cylinder (1 will exhaust through the bore is while the compressed fluid, in reduced volume, will be admitted below said piston in a manner to gradually restore the parts to the normal position, as shown in Fig. 2.

In Fig. 2, the relation of parts is such that the piston e is just about to descend to force the metal from the cylinder 01.

The gradual return of the piston or plunger 0 to normal prevents excessive splashing of the metal and does not reduce the capacity ofthe machine since it is during this interval that a casting or castings are drawn from the die. I

In a machine made in accordance with our invention, we not only secure the requisite varia'ble'pressure within the pressure cylinder 6 with a constant power applied to the power cylinder, and the maximum application of his pressure when the mold cavity is completely filled, but pressure conditions with all castings-made will be uniform with a resultant uniformity in the product from any die.

- It is not our intention to limit the invention to the precise details of construction shown in the accompanying drawings, it being apparent that such may be varied 'without departing from the spirit and scope of the invention.

Having described the invention, what we claim as new and desire to have protected by Letters Patent is 1. A casting apparatus embodying therein a melting pot, a pressure cylinder communicating therewith, a plunger'mounted in said cylinder, an actuating lever, one arm of which is operative upon said plunger, a power cylinder, a piston mounted therein, operative connections between said piston v and. the other arm of said lever, connections between sald power cyllnder and asource of fluid under pressure, and a valve mechanism controlling the flow of said fluid to and from said power cylinder.

2. A casting apparatus embodying therein a pressure cylinder adapted to receive molten metal and means forcing the molten metal 'from said cylinder comprising a power cylinder, means controlling the flow of fluid under pressure to and from said power cylinder, and connections between said piston and said plunger such that a' constant speed of and power exerted by said piston will cause a variable speed of, and a gradually increased power exerted by, said plunger in forcing metal from said pressure cylinder.

3. A casting apparatus embodying therein a. melting pot, a pressure cylinder communicating therewith, a plunger mounted in said cylinder,'an actuating lever, one arm of which is operative upon said plunger, a power cylinder, a double acting piston mounted therein, operative connections between said piston and the other arm of said lever, connections between the opposite ends of said power cylinder and the source of fluid under pressure, and a valve mechanism adapted to alternately connect the opposite sides of said piston with said source of fluid supply and simultaneously exhaust the fluid from the other side of said piston from that into which the fluid is permitted to flow.

4. A casting apparatus embodying therein a melting pot, a pressure cylinder. communicating therewith, a plunger mounted in said cylinder, an actuating lever, one arm of which is operative upon said plunger, a power cylinder, a double acting piston mohnted therein, operative connections be tween said piston. and the other arm of said lever, connections between the opposite ends of said power cylinder and the source of fluid underpressure, and a variable operative valve mechanism adapted to alternately connect the opposite sides of metal from said cylinder comprising apower I cylinder, a plunger mounted in said pressure cylinder, a double acting piston mounted in said owcr cylinder, a valve mechanism adapted to alternately permit fluid under pressure to fl-o w to opposite sides of said i piston and simultaneously exhaust the fluid from the other side of said piston from that into which the fluid is permitted to flow, and connections between saidpiston and said plunger, such that a constant speed of, and power exerted by,'said piston will cause a variable speed of, and a gradually increased power. exerted by, said plunger in forcing metalfrom said ressure cylinder.

6. A casting apparatus embodying therein a pressure cylinder adapted to receive molten metal and means forcing the molten metal from said cylinder comprising a power cylinder, a plunger mounted in said pressure cylinder, a double acting piston m'ounted in said'power cylinder, a variably operative valve mechanism adapted. to alternately permit fluid under pressure to flow to opposite sides of said piston and simultaneously exhaust the fluid'from the other side of said piston from that into which the fluid is. permitted to flow, and connections between said piston and said plunger such that a constant speed of and power, exerted by said piston will cause a variable speed of, and a gradually increased power exerted by, said plunger in forcing metal from said pressure cylinder.

7. In a casting apparatus, the combination of a pressure cylinder adapted to receive molten metal, a plunger therein, an actuating lever, one arm of which is operative upon-said plunger, a reciprocating member,

guiding means for the same, a link pivotally connecting said member with the other arm ofsaid lever, and power means for re ciprocating said member, said lever and link being so arranged that the leverage exerted upon said plunger increases during the operative stroke of said plunger.

JOHN KRALUND. MARCUS STERN.

Witnesses as to Kralund:

CHARLES PACK, ARTHUR S. HUMBLE.

Witnesses as to Stern:

JOHN A. TALLMAN,

S. M. Heron. 

